With Manual Transaxle

Check the CV-boots for rips and tears. Check for grease leaking from the CV-boots. Check the boot bands for damage. Replace any component if found to be defective.

Overhaul

Specific to:

Mazda 6 2003

Mazda 626 1999-2002

Mazda Miata 1999-2004

Mazda Protege 1999-2003

Mazda Protege5 2002-2003

Before servicing the vehicle, refer to the Precautions section.

Two types of CV-joints are used. The inboard CV-joints are the tri-Pot type. All outboard CV-joints are Birfield type. The Birfield CV-joint cannot be disassembled; if an outboard CV-joint boot needs replacement, the inboard CV-joint must be removed. If the outboard CV-joint needs to be replaced, replace the entire halfshaft as an assembly.

Remove the halfshaft from the vehicle and clamp it in a vise equipped with jaw caps, to prevent damage to the machined surfaces. Do not allow the vise to contact the boot or its clamps.

Remove the large boot clamp from the inboard CV-joint, using side cutters. After removing the clamp, roll the boot back over the shaft.

NOTE

Check the grease for contamination by rubbing it between 2 fingers. Any gritty feeling indicates a contaminated CV-joint, in which case the entire CV-joint must be disassembled, cleaned and inspected. If the grease is not contaminated and the CV-joint has been operating satisfactorily, continue with the boot replacement procedure and add the required lubricant.

Paint alignment marks on the outer race and shaft for assembly reference. Remove the wire ring bearing retainer and remove the outer race.

Paint alignment marks on the tri-pot bearing and shaft for assembly reference. Remove the tri-pot bearing snapring and, using a brass drift and hammer, remove the tri-pot bearing from the shaft.

Remove the small clamp and remove the inner boot from the halfshaft. If the boot is to be reused, wrap the shaft splines with tape before removing.

If the outer CV-joint boot is to be replaced, remove the clamps and slide the boot off the shaft from the inboard side.

To install:

If the outboard boot was removed, slide the boot onto the shaft from the inboard side. Wrap tape on the splines before installing to protect the boot.

Install the inboard boot and remove the tape from the shaft.

Install the tri-pot assembly on the halfshaft. Tap the assembly onto the shaft using a hammer and brass drift. Install the tri-pot assembly retaining ring.

Fill the CV-joint outer race with high temperature CV-joint grease. Install the outer race over the tri-pot joint and install the wire ring bearing retainer.

Position the CV-joint boot(s). Make sure the boot is fully seated in the grooves in the shaft and outer race.

Insert a small prybar with rounded edges between the boot and the outer bearing race to allow trapped air to escape from the boot. Install new boot clamps.

Wrap the clamps around the boots in a clockwise direction, pull tight with pliers and bend the locking tabs to secure in position.

Work the CV-joint through its full range of travel at various angles. The joint should flex, extend and compress smoothly.

Install the halfshaft into the vehicle.

Removal & Installation

Before servicing the vehicle, refer to the Precautions section.

Drain the transaxle oil.

Remove or disconnect the following:

Wheels

ABS sensor, if equipped

Splash shield, if equipped

Raise the staked portion of the hub locknut with a hammer and chisel.

Lock the hub by applying the brakes and remove the nut.

Fig. Exploded view of a typical halfshaft mounting-Except Mazda 3

Remove or disconnect the following:

Stabilizer bar from the lower control arm

Cotter pin and nut from the tie rod end ball stud

Tie rod end from the knuckle

Transverse member, on the 626

Lower ball joint pinch bolt and nut

Lower ball joint from the knuckle

If removing the left side shaft on 626 with automatic transaxle, proceed as follows:

Suspend the engine using engine support tool 49 G017 5A0.

Remove the engine mount member.

Position a prybar between the inner CV-joint and transaxle case. Carefully pry the halfshaft from the transaxle being careful not to damage the oil seal. If equipped with a right side intermediate shaft, insert the prybar between the halfshaft and intermediate shaft and tap on the bar to uncouple them.

Pull outward on the hub/knuckle assembly, push the outer CV-joint stub shaft through the hub and remove the halfshaft. If the halfshaft is stuck in the hub, install the old hub nut to protect the stub shaft threads. Tap on the nut, using only a soft mallet, to remove the halfshaft.

NOTE

Install plug tool 49 G030 455 into the transaxle after removing the halfshaft, to keep the differential side gear in position. If the gear becomes positioned incorrectly, the differential may have to be removed to realign the gear.

Remove the intermediate shaft, if necessary, by removing the support bearing bolts and pulling the shaft from the transaxle.

To install:

Install or connect the following:

NOTE

If equipped, push the halfshaft into the intermediate shaft.

New circlip on the end of the intermediate shaft, if removed, with the end gap facing upward.

Intermediate shaft in the transaxle, being careful not to damage the oil seals